U.S. patent application number 11/985692 was filed with the patent office on 2009-05-21 for gas cooking appliance with removable burners and useable work area.
This patent application is currently assigned to CFOM INC.. Invention is credited to Michael J. Grassi, Anne C. Sullivan.
Application Number | 20090126715 11/985692 |
Document ID | / |
Family ID | 40639098 |
Filed Date | 2009-05-21 |
United States Patent
Application |
20090126715 |
Kind Code |
A1 |
Grassi; Michael J. ; et
al. |
May 21, 2009 |
Gas cooking appliance with removable burners and useable work
area
Abstract
A gas cooking appliance for use with at least one removable
burner, the cooking appliance including a structural housing
supporting a cooktop surface having at least one convertible area
for use with the at least one removable burner. When the at least
one removable burner is operable with the cooking appliance, it
resides above the convertible area and is supplied a fuel mixture
from the cooking appliance by a gas-to-air type fuel supplier.
According to various preferred embodiments there are provided a gas
shutoff device for stopping the flow of gaseous fuel to the
removable gas burner when the burner is relocated or not properly
installed to the appliance proper; and an interlock so that during
cooking, the removable burner does not move about in an unsafe
way.
Inventors: |
Grassi; Michael J.;
(Somerset, PA) ; Sullivan; Anne C.; (Somerset,
PA) |
Correspondence
Address: |
Fay Sharpe LLP
1228 Euclid Avenue, 5th Floor, The Halle Building
Cleveland
OH
44115
US
|
Assignee: |
CFOM INC.
|
Family ID: |
40639098 |
Appl. No.: |
11/985692 |
Filed: |
November 16, 2007 |
Current U.S.
Class: |
126/39R |
Current CPC
Class: |
F24C 3/126 20130101;
F24C 15/10 20130101 |
Class at
Publication: |
126/39.R |
International
Class: |
F24C 3/00 20060101
F24C003/00; F24C 3/02 20060101 F24C003/02; F24C 3/06 20060101
F24C003/06 |
Claims
1. A gas cooking appliance comprising: a structural housing; a
cooktop surface supported by said structural housing; a convertible
area defined on said cooktop surface, wherein said convertible area
is imperforate; and, a gas-to-air type fuel supplier supported by
said structural housing for selectively delivering a fuel and
oxidizer mixture to an associated burner when said associated
burner is connected to said gas-to-air type fuel supplier and
wherein said fuel supplier is positioned above said convertible
area.
2. The cooking appliance of claim 1, wherein said fuel supplier is
positioned outside a periphery of said convertible area.
3. The cooking appliance of claim 1, wherein said fuel supplier is
movable in relation to said cooktop surface.
4. The cooking appliance of claim 1, wherein said fuel supplier
interlocks with said associated burner.
5. The cooking appliance of claim 1 which further comprises: a
normally closed fluid flow device in communication with said fuel
supplier such that fuel flow to said fuel supplier stops when said
associated burner is not selectively supported above said cooktop
surface.
6. A gas cooking appliance comprising: a structural housing; a
cooktop surface supported by said structural housing; a fuel
supplier supported by said structural housing for selectively
delivering a fuel mixture above said cooktop surface to an
associated burner selectively supported by said cooktop surface,
said fuel supplier being spaced outwardly from an outer periphery
of said cooktop surface.
7. The cooking appliance of claim 6, wherein said cooktop surface
is entirely apertureless.
8. The cooking appliance of claim 6, wherein said fuel supplier, in
combination with said associated burner, entrains nearly all
primary air from above said cooktop surface.
9. The cooking appliance of claim 6, wherein said associated burner
selectively interlocks with said fuel supplier and is selectively
in fluid communication therewith.
10. The cooking appliance of claim 6 which further comprises a
normally closed, fuel flow device in fluid communication with said
fuel supplier, such that fuel flow to said fuel supplier stops when
said associated burner is not selectively supported by said cooktop
surface.
11. A gas cooking appliance comprising: a structural housing; a
fuel supplier supported by said structural housing for selectively
delivering a fuel mixture; a burner functionally connected to said
fuel supplier for receiving said fuel mixture from said fuel
supplier; a cooktop surface supported by said structural housing,
said cooktop surface selectively supporting said burner and being
useable as a work area when said burner is not being supported;
and, a normally closed, fuel flow device in fluid communication
with said fuel supplier, such that fuel flow to said fuel supplier
stops when said burner is not selectively supported by said cooktop
surface.
12. The cooking appliance of claim 11, wherein said fuel flow
device includes a normally "closed" valve or regulator that
actuates to an "on" position when said burner is selectively
interlocked above said cooktop surface.
13. The cooking appliance of claim 11, wherein said fuel flow
device includes a flame safety valve with a thermal-electric
circuit that becomes electrically complete when said burner is
functionally connected to said fuel supplier.
14. The cooking appliance of claim 11, wherein said fuel flow
device includes an operator control receiver that interlocks to an
operator control transmitter for permitting selective delivery of
said fuel mixture when said burner is functionally connected to
said fuel supplier.
15. The cooking appliance of claim 11, wherein the functional
connection of said burner and said fuel supplier includes an
interlock, with one or more degrees of movement, between said
burner and said fuel supplier.
16. A gas cooking appliance that comprises, in combination: a
cooktop surface supported by an associated housing, said cooktop
surface having a useable work area with no apertures extending
through it; at least one burner that, during normal operation,
interlocks with said appliance and is supported above said work
area; and a gas-to-air type fuel supplier comprising at least one
orifice that delivers a fuel and an oxidizer to said burner when
said burner is located above said work area.
17. The cooking appliance of claim 16, further comprising a first
connecting element defined on said at least one burner and a second
connecting element defined on at least one of said appliance and
said fuel supplier in order to interlock said at least one burner
with the appliance.
18. The cooking appliance of claim 16, wherein said at least one
burner can be removed from said cooktop surface by rotating
upwardly.
19. The cooking appliance of claim 16, wherein said at least one
burner can be removed from said cooking appliance by lifting
upwardly.
20. The cooking appliance of claim 19, wherein said at least one
burner can be removed while it is kept in an orientation
approximately parallel to said cooktop surface.
21. A gas cooking appliance comprising: a structural housing; a
cooktop surface supported by said structural housing; a convertible
area defined on said cooktop surface, wherein said convertible area
is planar and has no apertures for passage of a gas therethrough;
and, a fuel supplier supported by said structural housing, said
fuel supplier having an orifice, wherein when an associated
removable burner is located above said convertible area and is
operational, gas egressing from said orifice is at near ambient
static pressure before being delivered to said associated removable
burner.
22. The cooking appliance of claim 21, wherein said associated
removable burner can be fully or partially removed from above said
convertible area.
23. The cooking appliance of claim 21 wherein said fuel supplier is
directly supported by said cooktop surface and indirectly supported
by said structural housing.
24. The cooking appliance of claim 21, wherein said convertible
area is useable as a work area when said associated removable
burner is not located above said convertible area.
25. The cooking appliance of claim 21 which further comprises a
normally closed, fuel flow device in fluid communication with said
fuel supplier, such that fuel flow to said fuel supplier stops when
said associated removable burner is not supported by said cooktop
surface
Description
FIELD OF THE INVENTION
[0001] The present disclosure relates to cooking appliances and the
like. Particularly, this disclosure relates to rangetops or
cooktops for gas appliances. More particularly, this disclosure
relates to a next generation of gas cooking appliances with
removable burners and a useable work area beneath.
BACKGROUND OF THE INVENTION
[0002] Studies have indicated that in the selection of cooking
appliances, consumers value three factors of relatively equal
importance: aesthetics, cleanability and performance. The popular
electric smoothtop ranges, i.e. those having a cooktop surface that
is flat and uninterrupted, score well in all three factors. They
have been available for several years now. With their smooth
uninterrupted cooktops, such electric smoothtops satisfy consumer
aesthetics by giving these appliances their sleek, modern
appearances. Cleanability needs are met by these smooth electric
tops in which the cooking areas have no apertures and/or surface
irregularities. Without apertures or irregularities, spilled matter
and/or other debris can not collect within these types of
rangetops.
[0003] For years, chefs and other cooking experts have preferred
the performance of gas over electric cooking. However, because no
gas surface rangetops have adequately addressed aesthetic and
cleanability, the general consumer market has tended away from gas
rangetops. There has been a gradual decline in gas cooking
appliance sales despite their performance advantage.
[0004] Gas surface rangetops typically incorporate a cooking vessel
support or grate on which a cooking pot or pan rests over a gas
burner projected through an opening in such rangetops. These gas
burners are loosely or rigidly secured to a chassis of the
appliance. In most modern applications, burners are typically
fixedly or loosely secured to the cooktop with a burner seal
arrangement that enhances cleanability. Such gas burner
arrangements are similar to those of conventional (i.e.
non-smoothtop) electric cooking ranges where an open heating
element protrudes through an aperture in the cooktop surface for
both heating and supporting the cooking pot or pan.
[0005] In the past few decades, there have been several different
attempts to duplicate an electric smoothtop with gas equivalents.
They include using: 1) a gas burner under the cooktop surface, i.e.
a gas smoothtop; 2) a gas burner assembly that passes through an
aperture in a planar cooktop surface with a separate grate above;
3) a gas burner that passes through an aperture with an integral
grate in the cooktop surface; 4) a full or partial burner assembly
that is integral with the cooktop surface, the grate being: (a)
part of the cooktop surface; (b) a non-integral portion of the
burner or (c) a separate component; and 5) an aperture in the
cooktop surface for a full or partial burner assembly with the
grate and/or burner being a part of that cooktop surface.
[0006] Perl U.S. Pat. Nos. 3,870,457 and 3,968,785 disclosed a gas
smoothtop range or cooktop having a powder blue flame rather than a
radiant type burner beneath their glass ceramic top. Herbert U.S.
Pat. No. 5,295,476 disclosed a radiant burner below the cooktop
plate to enable a gas radiant smoothtop that might compete more
effectively with conventional open flame burners.
[0007] Schott Glas developed a `gas-under-glass` smoothtop that
intended to address the cooking application, control and venting
issues with radiant burner heating. That arrangement offered no
distinct advantage compared to electric smoothtops, however. Such
configurations actually raised the price of gas smoothtops
significantly as compared to electric smoothtops due to: (i) the
complexity of combustion venting; and (ii) the need for additional
safety controls. Also, with a gas burner under a smoothtop surface,
the cooking performance advantage of being able to visually
identify heat output and make rapid adjustments thereto was
lost.
[0008] Bennett et al U.S. Pat. No. 5,046,477 disclosed a glass
cooktop having a burner opening with an arrangement for supporting
the gas burner independent of the cooktop. The cooktop apparatus of
Taplan et al U.S. Pat. No. 6,032,662 included a cooktop panel of
glass ceramic, glass or ceramic in a structural housing. That
cooktop panel had a cutout for accommodating a gas burner held by
an assembly with a collar that annularly overlapped a portion of
panel at the cutout. The aforesaid collar had an inner edge which
defined a first abutment for gas burner engagement. A resilient
metal element attached to that burner and extended outwardly
therefrom for engaging with a lower side of the panel. That lower
side defined a second abutment against which the metal element
applied force to hold the burner on the panel via the collar and
resilient element. A seal clamp between the collar and panel
prevented spillage from reaching the structural housing through the
cutout.
[0009] Taplan et al U.S. Pat. No. 6,170,479 disclosed attaching an
atmospheric gas burner to an opening in a glass or glass-ceramic
cooking surface for reducing assembly time, the number of
components required and easier cleaning of an assembled unit. Arntz
et al U.S. Pat. No, 6,173,708 disclosed a gas burner mounting
assembly with an injector whose main body portion was positioned
between a chassis member of the appliance and a ceramic based
cooktop. That injector was mechanically secured to the cooktop for
allowing its gas injector to flex with that cooktop.
[0010] Taplan U.S. Pat. No. 6,209,534 disclosed a glass-ceramic,
molded cooktop plate with a covered, upwardly projecting portion
that formed a gas/air mixing chamber for a burner. Between the
cover and projecting portion, burner ports were provided to burn a
gas/air mixture. Miller U.S. Pat. No. 6,148,811 showed a combined
burner and grate structure integral with its cooktop surface.
[0011] With any cooktop made from glass, breakage can occur during
its manufacture. Defects start as micro-cracks, which lead to
stress risers unavoidable in the normal processes for drilling an
aperture in such products. Breakage can also occur during usage,
especially with a grate located near or on the burner proper.
Impact with the burner/grate causes a high bending moment for such
cooktops. With cooktops made from thermally- or chemically-tempered
soda lime glass, thermal shock from high temperatures proximate the
burner can also cause breakage. For the latter glass, a maximum
temperature limit must be observed to retain its temper and
mechanical--thermal loads.
[0012] Braccini U.S. Pat. No. 6,257,228 addressed micro-crack
breakage and cleanability by creating a molded, raised part above
the surface. That part prevented liquid food from falling through
and reaching the burner proper. However, additional thermal
processing raised the cost of such cooktops, and holes still have
to be drilled therethrough.
[0013] Other solutions for preventing the glass from overheating
and breaking use large diameter borings and place a sheet metal pan
underneath. The edge of each boring sits in a collar. With that
practice, aesthetics is lost and cleaning these large borings
becomes an issue.
[0014] Gabelmann U.S. Pat. No. 6,505,621 addressed thermal breakage
for a cooktop having at least one gas burner cutout by applying a
reflective coating to the upper side of his cooktop plate. While
reducing the thermal load to the plate, it added manufacturing
costs.
[0015] Both gas and electric cooktops suffer from the disadvantage
of requiring a dedicated burner/heating position for cooking. And
while burners of different power or heating characteristics are
available, they are still relatively fixed in number, variety and
location on a given cooktop. This limits the user in choice of
cooking style or function. Electric smoothtops have tried to
partially address this problem with "bridge burners", i.e., two
non-concentric circular burners morphed into an oblong or ovular
burner ring useful for griddles, long fish pans and the like. Such
a combination has been disclosed for gas cooktops in Yam et al
Published U.S. Application No. 2005/0142511. These gas burners tend
to heat individual segments unevenly when the bridge is
deactivated, however.
[0016] To compensate for dedicated heating positions, commercially
available gas rangetops (as well as electric) such as that
disclosed in Berlik U.S. Pat. No. 4,457,293 have modular burner
cartridges, otherwise known in the art as "modular cooking units",
"surface burner units", "drop-in" or "plug-in" cartridges. Such
rangetops have recessed burner boxes or burner pans otherwise known
in the art as "compartments" in the rangetop's top surface (cooktop
surface). These units or cartridges are dropped into a compartment
to form an arrangement similar to conventional gas surface
rangetop. For example, one rangetop may include a gas burner
cartridge for a first compartment and a grilling cartridge for a
second compartment.
[0017] While permitting a change in burner types, these cartridges
still require a complete "unit", i.e., cooktop surface, burner, and
housing in which all components are fastened together. As such,
these cartridges tend to be bulky and therefore cumbersome to
switch between. In addition, the burner cartridge system also
offers no significant burner performance especially when compared
to a dedicated, fixed-position gas-burner rangetop. This is
partially due to the cartridge/rangetop configuration, which places
more overall constraints on the gas circuit's performance.
[0018] Beach et al U.S. Pat. No. 4,705,019 disclosed a range with
selectively interchangeable burners. The latter burners were
lighter in weight as they did not require a complete "unit".
Instead, these burners were installed in the compartment (burner
box). Such compartments would be difficult to clean as the
compartment bottom is significantly below the cooktop surface. The
compartments are below countertop level, relatively deep, and
permanently fixed in place. Switching between surface burner
cartridges could also be quite cumbersome for similar reasons.
Regardless, the burner well area, i.e. that portion of the burner
cartridge, or the bottom of the burner pan into which the modular
burner cartridges drop, precludes its use as a food preparation or
work area.
[0019] Modularity is a good marketing strategy and a useful
concept. It addresses the fundamental need that various cooking
styles require different burners. Modularity frees the user from
the limitations of a fixed-position rangetop while allowing one to
add (or change) burners to match the cooking functions needed.
Modularity is also beneficial during the initial purchase. It
allows consumers to buy only what they need with the option of
adding more burners later to meet changing needs or
preferences.
[0020] For any smoothtop (electric or gas) made from a brittle
plate, damage to the flat cooking surface can result by the mere
dropping of a cook pan. Such damage may require replacing the whole
cooking surface. The ability to change cooktop surfaces in case of
breakage, while adding greater modularity with changing smoothtop
colors and/or design motifs would be desirable. It would also
supply an advantage not present with current cooktops having
glass-ceramic top surfaces.
[0021] Hence, there remains a need for gas cooktops that: (a)
provide the performance characteristics of conventional gas
cooking; (b) improve modularity; (c) rival the cleanability and
aesthetics of an electric smoothtop without having the burner
hardware mounting issues at the manufacturing level; and (d)
permits using the area in the vicinity of the burner head, when not
used for cooking, as a work surface area without burner hardware
obstructions.
SUMMARY OF THE INVENTION
[0022] There is provided a cooking appliance for use with one or
more removable gas burner assemblies. The cooking appliance
comprises a cooktop surface having a convertible area for use with
a plurality of selectively removable burner assemblies. When made
operable, these burner assemblies reside atop the convertible area
and are supplied gas from the appliance proper. Preferred
embodiments add means for a normally "closed" fluid flow device
that stops gas flow to the burner when the burner is removed from
the convertible area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a perspective view schematically showing one
embodiment of the disclosure as a freestanding appliance;
[0024] FIG. 2A is a perspective view of the appliance from FIG. 1
with a removable burner installed on its right side;
[0025] FIG. 2B is a schematic view of the cooktop surface having a
fan duct:
[0026] FIG. 2C is a schematic view of the cooktop surface having a
peripheral lip;
[0027] FIG. 2D is a schematic view of the cooktop surface having
apertures;
[0028] FIG. 2E is a schematic view of a `cutting board` type
cooktop surface;
[0029] FIG. 3A is a schematic view of a second embodiment showing
the disclosure as a slide-in cooktop;
[0030] FIG. 3B is an exploded schematic view of a portion of the
slide-in cooktop;
[0031] FIG. 3C is a schematic view of a fuel supplier and a fuel
supplier mate;
[0032] FIG. 4A is a perspective view of a third embodiment
schematically showing the disclosure as a drop-in cooktop;
[0033] FIG. 4B is a schematic view of the FIG. 4A embodiment with
its cooktop surface removed;
[0034] FIG. 5 is a perspective view of a fourth embodiment
schematically showing a drop-in cooktop with electronic
controls;
[0035] FIG. 6A is a detailed fuel circuit schematic showing a
gas-to-air type fuel supplier delivering fuel mixture to a
removable burner as per one embodiment of this disclosure;
[0036] FIG. 6B is a fuel circuit having a gas-to-air fuel supplier
having two orifices; delivering fuel mixture to a removable burner
having one fuel supplier mate with two entrances;
[0037] FIG. 6C is a fuel circuit showing two fuel suppliers
delivering fuel mixture to a removable partitioned `single` burner
having one fuel supplier mate with two entrances;
[0038] FIG. 6D is a fuel circuit schematic showing a gas-to-air
type fuel supplier delivering fuel mixture to a removable burner as
per a second embodiment of this disclosure;
[0039] FIG. 6E is a close up, cross-sectional schematic view of the
fuel supplier and fuel supplier mate from FIG. 6A having a partial
interlock;
[0040] FIG. 6F is a close up, cross-sectional schematic view of the
fuel supplier and fuel supplier mate from FIG. 6A;
[0041] FIG. 6G is a perspective schematic view showing an
embodiment of the fuel supplier and fuel supplier mate having a
partial interlock shown in FIG. 6A;
[0042] FIG. 6H is a close up schematic showing a side view of a
removable burner having a fuel supplier with a partial interlock
similar to that shown in FIG. 6G;
[0043] FIG. 7 is a first block diagram schematic showing an
interlock interrelationship between the elements of the
disclosure;
[0044] FIG. 8 is a second block diagram schematic showing an
alternative interlock interrelationship between the elements of the
disclosure;
[0045] FIG. 9 is a third block diagram schematic showing an
interlock with partial interlocks and interrelationship between the
elements of the disclosure;
[0046] FIG. 10A is a perspective view of a representative removable
burner assembly for use in the present disclosure;
[0047] FIG. 10B is an enlarged schematic of the electrical receiver
from the removable burner assembly in FIG. 10A;
[0048] FIG. 11 is a detailed side view of one igniter embodiment
for use with the present disclosure;
[0049] FIG. 12 is a perspective view of a partially dissembled,
cooktop appliance according to one embodiment of the
disclosure;
[0050] FIG. 13A is a perspective view showing a partial view of a
preferred hinge assembly for the fuel supplier of this disclosure,
said hinge assembly having multiple degrees of movement;
[0051] FIG. 13B is a perspective view showing the FIG. 13A fuel
supplier mate moving vertically upward, in its first degree of
movement;
[0052] FIG. 13C is a perspective view showing the FIG. 13A fuel
supplier mate moving in its second degree of movement, rotationally
upward;
[0053] FIG. 14A is a detailed fuel circuit with an electromagnetic
gas shutoff;
[0054] FIG. 14B is a detailed fuel circuit with a first alternative
gas shutoff;
[0055] FIG. 14C is a detailed fuel circuit with a second
alternative gas shutoff;
[0056] FIG. 14D is a detailed fuel circuit with a third alternative
gas shutoff;
[0057] FIG. 14E is a detailed fuel circuit from FIG. 14D with
additional gas shutoffs incorporated;
[0058] FIG. 14F is a detailed fuel circuit having a fourth
alternative gas shutoff;
[0059] FIG. 14G is a detailed fuel circuit with a fifth alternative
gas shutoff;
[0060] FIG. 14H is a detailed fuel circuit with a sixth alternative
gas shutoff;
[0061] FIG. 14I is a detailed fuel circuit with a seventh
alternative gas shutoff;
[0062] FIG. 15A is a perspective schematic view showing one
embodiment of the disclosure as a freestanding cooking
appliance;
[0063] FIG. 15B is a fuel circuit for a removable burner having an
operator control in accordance with one embodiment; and
[0064] FIG. 15C is a perspective view showing an embodiment of fuel
supplier and operator control receiver interfacing with a removable
burner having its own operator control and transmitter.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0065] As used herein, the terms "gas burner", "burner", and
"burner assembly" are all synonyms that describe a "gas burner
assembly" made of separate or integral components, which function
adjacent to, operably over, on, atop or otherwise "above" a portion
of a cooktop surface of an appliance. The `burners` of this
disclosure, in contrast to prior art `burners` may be "removably"
installed and are not intended to protrude or mount through an area
on the cooktop surface that has apertures extending therethrough
for supplying gas to the burner.
[0066] Unless otherwise stated, these gas burners have the ability
to: [0067] a. receive and combust fuel (natural gas, propane,
butane, European category I, II, or III gas mixes, etc.) for
cooking food; and [0068] b. support a cooking vessel; and [0069] c.
manage the energy released from combustion, not only for cooking,
but also to prevent overheating the cooktop surface, if necessary,
using a heat shielding device for keeping areas of the cooktop
surface cooler during cooking; and [0070] d. be washed, in whole or
in part, in a typical dishwasher.
[0071] "Burner" means a gas burner, gas burner assembly, or burner
assembly.
[0072] "Convertible area" means an unimpeded area bounded by a
single perimeter that is functional as a kitchen countertop area
and is appropriate for such tasks as food preparation or even
preparing a written grocery list, when a burner is not mounted
above (including "over", "on", "atop" and "to") this convertible
area; and, that area has no apertures extending therethrough for
supplying gas to the burner.
[0073] "Removable burner" means a burner which may be fully or
partially relocated from being above, over, or on a convertible
area, so that when the burner is relocated, even temporarily, the
convertible area can be used as work area.
[0074] "Imperforate" means having no opening or aperture;
specifically lacking the usual or normal opening that a fuel
mixture must pass through in conventional gas cooktops with one or
more apertures beneath their respective burners.
[0075] "Interlock" means `to make a connection` or is `a
connection` between a burner and a cooking appliance, so as to
prevent the burner from moving about with respect to the cooking
appliance in an unsafe way during cooking when the burner is
mounted over, mounted on, mounted above, or mounted to a
convertible area. When `interlocked` the fuel supplier is able to
properly deliver gas to the removable burner.
[0076] "Support" means to fasten, hold, secure, connect, attach,
join, suspend or the like, a first element directly or indirectly
to a second element; and if indirectly, then any intermediary
elements between the first and second element are fastened, held,
secured, connected, attached, joined, suspended or the like to each
other.
[0077] "Structural housing" means a chassis, frame, housing,
casing, body or the like, to which elements may be connected so as
to form a whole or partial appliance structure.
[0078] "Fuel supplier" means a fuel circuit outlet having one or
more components, which delivers a fuel mixture to a mating
component of the removable burner. The fuel supplier need not be
physically connected to the mating component of the burner assembly
but may be functionally connected such as for a gas-to-air type
connection.
[0079] "Fuel supplier mate" means a portion of a removable burner
which permits fuel mixture to be received from one or more fuel
suppliers.
[0080] "Fuel mixture" is a single gas or mixture of gases with or
without an oxidizer component.
[0081] "Fuel circuit" means the combination of gas piping that is
fluidly connected by being in serial, being in parallel, or being
in a combination of serial and parallel connections; the gas piping
having one or more inlets, and one or more outlets; and, between
the inlets and the outlets having one or more fluid control devices
in fluid communication with the gas piping for controlling fuel
delivered to the inlets and supplied to the outlets so that the
mass flow of fuel into all the inlets equals the mass flow of fuel
out of all the outlets.
[0082] "Proper fluid communication" means the inlet mass flow of
the fluid equals the outlet mass flow of the fluid, such that there
are no leaks of the fluid.
[0083] "Properly installed to the appliance" means being able to
cook with the removable burner; that is, the removable burner is in
proper fluid communication with the respective fuel supplier and
must be mounted atop, mounted over, mounted above, or mounted on
the convertible area.
[0084] "Cooktop surface" means the top or upper surface of a
cooking appliance structure, which when used for cooking,
accommodates at least portions of one or more burners. The cooktop
surface excludes lids or covers mounted to the appliance. When the
appliance is properly installed for use in a kitchen, the cooktop
surface is located at, or spaced nearest to, the height of a
kitchen countertop. The cooktop surface may have sidewalls; but the
sidewall height is less than about half a burner assembly height.
The cooktop surface may include apertures for other functions such
as a fan duct, or area for operator controls. The cooktop surface
of this disclosure has one or more convertible areas. A convertible
area may be a pan-like area extending parallel to the cooktop
surface. If present, pan sidewalls and a pan bottom require no
apertures extending through either of them for supplying fuel to a
burner.
[0085] "Smoothtop" means the planar, relatively impermeable,
pore-free top surface of a cooking appliance structure. The
smoothtop has one or more defined cooking vessel support areas for
supporting a cooking vessel during cooking, and has a heating
source located beneath the bottom surface of the smoothtop in this
area. The cooking vessel support area is apertureless. The cooking
vessel support area may also be a cooking area if the smoothtop
transfers heat from the cooking vessel area in contact with the
cooking vessel. Conventional electric smoothtop appliances, or
previously developed gas-under-glass appliances, have this
arrangement. Induction smoothtops do not have a cooking area, as
that area is part of the cooking vessel. All smoothtops have a
cooking vessel support area located on the top surface, and a
heating source located below the bottom surface. When a cooking
vessel is not mounted on the cooking vessel support area, the
latter can be used as a work area or work surface.
[0086] "Cooking area" means the area at which heating takes place
for cooking. Based upon the principles of heat transfer, the
cooking vessel receives heat flux. The cooking appliance generates
this heat flux by radiation, conduction, or convection at the
cooking area. Alternatively, electromagnetic waves can generate
eddy currents at a cooking vessel, which also creates "heat", as in
induction heating, but those eddy currents still indirectly
generate a heat flux to the cooking vessel. Based on the type of
heating source and the burner location, the cooking area may vary
in location. For a conventional gas burner of the "blue-flame"
type, the cooking area consists of the flames themselves, and
indirectly both the burner head, which may radiate, and the cooking
vessel support, which may conduct heat to the cooking vessel.
[0087] A "rangetop" is synonymous with a surface cooktop, surface
rangetop, cooktop, cooker, cook stove, flat top, top flat, hob
and/or stovetop. They all describe an appliance used to cook foods
in a cooking vessel over a heat source. An "appliance" has a
"rangetop" but may include still other appliance features, in
combination, like an oven, microwave or even a refrigerator
unit.
[0088] In the accompanying Figures, common features among the
various embodiments are commonly numbered, with the same or
substantially similar components being assigned the same last two
digits in the series. Referring now to the drawings, FIG. 1
schematically depicts a free standing cooking appliance 110.
Otherwise known as a range, cooking appliance 110 includes a
structural housing 112 in which an oven 114 may also be housed.
Range 110 includes a cooktop surface 117 for gas cooking. Cooktop
surface 117 has at least one convertible area 101. In some views,
the convertible area is shown separately, with a phantom line. In
other examples, the convertible area may be considered all of
cooktop surface 117 as per FIG. 1. Regardless of its size and
relative dimensions, convertible area 101 is apertureless, i.e. has
no apertures extending through said area, or having no apertures
through which other appliance components must pass. In that
instance, an apertureless convertible area may also be said to be
"imperforate", as defined above.
[0089] FIG. 1 shows what a cooking appliance 110 might look like
when not in use for cooking. Particularly, gas burners could be
completely disconnected from the appliance and removed and stored
leaving convertible area uncluttered, thereby having a similar
appearance to that of a conventional electric smoothtop range. Fuel
suppliers 122 for cooking appliance 110 are shown as being located
external to the convertible area. A fuel supplier 122 supplies gas
to a burner head that is part of a removable burner assembly. Fuel
supplier 122 can be located in several areas provided that the fuel
supplier 122 is not located in the convertible area when not used
for cooking. This results in a convertible area having an
apertureless surface. A fuel supplier can be movable as will be
later described more fully for FIGS. 14G and 14I, or fixed to the
structural housing 112 and external to the convertible area. An
exploded schematic and a more detailed schematic of a fixed fuel
supplier is shown and described later for FIGS. 3B and 3C. As
shown, fuel suppliers 122 are fixedly located at panel 115 that
extends along the back of cooktop surface 117. A control panel 104
with operator controls 124 is shown external to convertible area
101. As will be shown in FIG. 2, when a removable burner assembly
is positioned over, onto or above cooktop surface 117, its burner
head (or heads depending on burner style) will be located within
the convertible area 101. Fuel supply to the removable burner from
the supplier will be more fully explained in FIG. 6A. However, in
FIG. 1, removable burner is properly and selectively located for
being supplied gas from a fuel supplier 122, and operator control
124 adjusts the amount of fuel flowing through that fuel supplier
and hence to the gas burner. The schematic at FIG. 1 shows operator
control 124 as an integral part of cooking appliance 110.
[0090] Oven 114 is controlled by an oven control on panel 115. Oven
control can also be located in other areas including with control
panel 104. Although a removable burner assembly is required for
cooking with this appliance, it need not be sold with same,
especially for modular applications. Consumers may purchase a range
like element 110 with separate removable burner assemblies that
best suit their cooking styles.
[0091] In FIG. 2A, the same cooking appliance as depicted in FIG. 1
is shown, but with cooking appliance 210 having an interlocked
removable burner assembly 236 with a rear and front burner head 220
located on the right side of cooktop surface 217. Removable burner
236 is supplied gas from its fuel suppliers 222. Removable burner
236 rests above or over cooktop surface 217 which has no apertures
in or through its convertible area 201. In this particular view,
two convertible areas are shown for clarity. It is to be
understood, however, that an appliance according to this disclosure
may have just one convertible area, or more than two separate
convertible areas as well.
[0092] Burner 236 covers a significant portion of the right side to
cooktop surface 217. For illustrative purposes, a cooking vessel
(CV) is shown resting on cooking vessel support or grate 218 above
rear burner head 220. Optionally, a heat shield (not shown) for
removable burner 236 may be used to reflect radiant energy during
cooking. A heat shield located on removable burner 236 would help
keep cooktop surface 217 relatively cooler. That will enable
manufacturers to make such cooktops from less heat resistant
materials, and include decorations and/or painted areas.
[0093] For clarity, cooktop surfaces in FIGS. 1 and 2, and later in
FIGS. 3-5 are all shown with a planar cooktop surface. Cooktop
surface need not be completely planar or apertureless, provided
that a convertible area may serve as a work area. FIGS. 2B through
2F show alternative cooktop surface configurations. None of these
alternative configurations is completely planar or featureless,
though. FIG. 2B shows that a fan duct 221 is located in the cooktop
surface, but the cooktop surface 217 still has convertible areas
201 which permit a work area. Convertible area 201 also has dimples
243 and/or protuberances 293 that do not impede cleaning but may be
used for burner location or other for other functionally reasons.
FIG. 2C shows cooktop surface 217 with an outer lip 229 at its
periphery, but having a convertible area 201 (two areas shown, but
equivalently can be encompassed by one) located internal to the
lip. FIG. 2D, shows a cooktop surface 217 having a convertible area
201 (one shown) but also having operator control apertures 202 for
mounting operator controls therethrough. FIG. 2E shows a `cutting
board` style cooktop surface 217 having one or more convertible
areas 201 with a recessed area 203 for drips on the outer periphery
of the convertible areas 201. The cooktop surfaces in FIGS. 1 and
2A-2E are for illustration. The cooktop surfaces of this disclosure
can take many forms provided the cooktop surface has at least one
convertible area.
[0094] FIG. 3A depicts a schematic of a slide-in type cooking
appliance 310 with a structural housing 312 and cooktop surface 317
for gas cooking. One or more removable burner assemblies 336 would
be located in convertible area 301 of appliance 310 when used for
cooking. When removable burner assembly 336 is removed, it is more
evident the extent to which cooktop surface 317 is truly
apertureless in convertible area 301 (two such areas shown) as in
FIG. 1.
[0095] Fuel suppliers 322, as better seen in exploded views in
FIGS. 3B and 3C, supply gas to removable burner assembly 336 via
fuel supplier mate 372. As shown, that supplier 322 is located
external to periphery of convertible area 301 at panel 315 along
the back of cooktop 317. It is to be understood, however, that
other locations such as the side or front of cooktop 317 are also
possible for fuel supplier 322.
[0096] A control panel 304 with operator controls 324 is located
external to convertible areas 301 of appliance 310 in FIG. 3.
Operator controls 324 may be used to adjust heat output for
removable burner 336 when the latter is properly installed on
cooktop 317 and operating. Removable burner 336 also includes a
grate 318 for supporting a cooking vessel, and an igniter 362 for
igniting the fuel delivered to burner head 320. As later described
for FIGS. 10A, 10B and 12, an electrical connector 373 may supply
power through a receiver 363 (better seen in FIG. 3C) on removable
burner 336 to ignition element 362.
[0097] FIG. 3B shows in partial cross section an exploded view of
the right rear section of appliance 310. FIG. 3C schematically
shows another view of same, but showing how burner assembly 336 may
be interlocked to the fuel suppliers 322. Also, both FIG. 3B and 3C
show a fuel supplier 322 of the gas-to-air type having an orifice
328 that supplies fuel to a removable burner having a gas
distribution tube entrance 332. As schematically depicted, the fuel
suppliers 322 and electrical connector 373 are connected in such a
way as to form an interlock to electrical receiver 363, thereby
keeping burner assembly from moving around when the removable
burner is mounted above the convertible area 301. Also shown and
will be further explained later, is gas shutoff device 305. As
depicted, this gas shutoff device is an electrically-operated,
normally-closed, gas valve. Gas shutoff device 305 is electrically
activated to an open position by interlocking the removable burner
336 to the appliance 310 proper. Here, electrical receiver 363 and
electrical connector 373, when connected, complete the electric
circuit for device 305 which supplies gas to fuel supplier 322
through gas conduit 334. Alternatively, removable burner 336 could
trigger an independent mechanically activated electrical switch or
connection, or equivalent to complete the electric circuit for
device 305.
[0098] The cooking appliance 410 in FIG. 4A is a drop-in type that
has one convertible area 401 and at least one operator control 424
and fuel supplier 422. It should be understood that alternate
configurations for appliance 410 may include additional operator
controls and fuel suppliers as shown for the appliances 110 of FIG.
1, 210 of FIG. 2A, and 310 of FIG. 3A. Such an appliance can be
mounted on a kitchen countertop, as long as it has a suitable gas
conduit extending therein to which the appliance can be
connected.
[0099] Drop-in cooking appliance 410 has a structural housing 412
and cooktop 417 for gas cooking. Different types of removable
burner assemblies will be located on convertible area 401 during
normal operation, i.e., when that appliance will be used for
cooking. After such burners are removed however, convertible area
401 of cooktop 417 is effectively apertureless and uncluttered. In
this state, convertible area 401 can be used for other purposes
including food preparation. A fuel supplier 422 at panel 415,
external to convertible area 401, supplies gas to its removable
burner assembly, much in the same way as was shown in FIG. 3B.
Other locations external to convertible area 401 are also possible
for fuel supplier 422. A control panel 404 with operator control
424 can also be located external to convertible area 401, said
control adjusting the amount of fuel flowing through fuel supplier
422 for when a removable burner is installed over cooktop 417 so as
to receive gas from fuel supplier 422. The aforementioned control
panel 404 and fuel supplier 422 are both shown extending from one
side of the appliance in this view. It is to be understood,
however, that the control panel and/or fuel supplier in this view
(and any variations thereof) may be extended from any side of an
appliance in alternative embodiments.
[0100] In FIG. 4B, the drop-in appliance 410 from FIG. 4A is shown
with its cooktop surface 417 removed from structural housing 412
thereby more closely resembling a box-type chassis. With that sort
of configuration, the compartment beneath surface 417 can be kept
empty for stowing an unused removable burner especially when a
portion or all of surface 417 is hinged via conventional means (not
shown). Alternately, a drawer, not shown, can be added to
structural housing 412. For some applications, it may be desirable
to minimize the relative depth of structural housing 412 for
facilitating installation in a countertop having one or more
cabinet drawers below. The schematic at FIG. 6G shows a fuel supply
that would work well for a drop-in appliance like the one shown in
FIGS. 4A and 4B. Such an appliance would be ideal for mobile homes
and campers.
[0101] FIG. 5 schematically shows another variety of drop-in
cooking appliance 510 with structural housing 512 depicted as box
type chassis having a low sidewall height, a cooktop surface 517
and a convertible area 501 (two are shown, but here again one area
may encompass both). A fuel supplier 522 (hidden from view)
delivers gas to fuel supplier mate 572 of removable burner assembly
536 of this appliance. The fuel supplier can be located at panel
515 along a back portion of cooktop 517. A control panel 504 with
operator control 524 can be located external to convertible area
501 therein. Operator control 524 is depicted in this figure as an
electronic control. Previously shown control elements 124, 224, 324
and 424 can also be electronic.
[0102] The grate 518 of FIG. 5 supports a cooking vessel and
further includes an igniter 562 at burner head 520. In addition, an
electrical connector 573 connects to igniter 562 and supplies power
to receiver 563 therein.
[0103] The operator control, element 124, 224, 324, 424, and 524 in
FIGS. 1 through 5, adjusts fuel flow to a fuel supplier
respectively shown as 122, 222, 322, 422, and 522. Although not
mandatory, it is desirable for operator safety to prohibit gas flow
unless a removable burner (like elements 236 and 336 and 536 in
FIGS. 2A, 3A, and 5, respectively), is: (a) in proper fluid
communication with the appropriate selected fuel supplier; and (b)
properly mounted above the convertible area.
[0104] In FIGS. 6A and 6B alternate representations for a fuel
supplier component 622 are schematically shown. Fuel supplier 622
can be substituted for earlier counterpart suppliers 122, 222, 322,
422 or 522.
[0105] FIG. 6A schematically details the basic elements of a fuel
circuit, otherwise known as a "fuel supply". Therein, a fuel
mixture is supplied from supplier 622 to removable burner assembly
636 with its fuel supplier mate 672. As shown, fuel supplier 622
has an orifice 628 (like element 328) which need not fluidly seal
or even mechanically connect to mate 672, so long as the latter's
entrance 632 (like 332 in FIG. 3C) is properly located with respect
to the outlet for orifice 628. Such locating may be performed
directly by fuel supplier mate 672 as will be shown in FIGS. 6D and
6F, or indirectly via the removable burner assembly 636, similar to
that shown in FIGS. 3B and 3C. Therefore, this type of fuel
connection, referred to as a `gas-to-air type` need not be a
physical fuel connection per se, but may be more of a functional
fuel connection.
[0106] A gas-to-air type fuel connection is explained by
Bernoulli's Principle, i.e. that an orifice converts a gas stream
under an initial pressure and velocity to a gas jet having higher
velocity and lower pressure with higher momentum and near zero
gauge pressure if that jet is released to atmosphere. The jet
velocity and momentum causes surrounding oxidizer (air) to be
entrained in the jet. That jet is more commonly called a `free` gas
jet since the gas therein is very near atmospheric pressure. That
jet is made as gas egresses the orifice. And it persists until the
jet enters the gas distribution conduit. Therein, the reverse takes
place and a portion of gas stream velocity converts to higher than
atmospheric pressure for overcoming pressure losses from fluid flow
friction.
[0107] Preferably, gas manifold 626, or its functional equivalent,
which is fluidly connected to gas control 630, is pressure
pre-regulated. An operator control, shown as hand knob 624 in FIG.
6A, adjusts gas control 630 for regulating the flow of gas 646
flowing through this system. It is to be understood that still
other types of operator control and gas valves may be used in
conjunction with this disclosure such as the electronic operator
control 524 shown in FIG. 5.
[0108] In the representative "fuel circuit", after receiving gas
from manifold 626, gas control 630 regulates the flow of gas 646,
through conduit 634, to orifice 628. That conduit 634, or manifold
626, can be rigid or flexible and may include a currently known
swivel joint, rotating joint or the like. If a flexible conduit was
desired, a fuel supplier like element 522 and/or panel 515 could be
made retractable, rotatable or both. That would allow such a fuel
supplier to be removed from its convertible area or cooktop surface
when not in use. Depending on the type of gas control used, it may
also be possible to completely eliminate the need for conduit-like
items altogether.
[0109] When there is gas flow 646, orifice 628 creates a gas jet
648. The diverging arrows at the outlet of orifice 628 in FIG. 6A
show such a gas jet entraining oxidizer (air) 696 from its
surroundings before entering a mixing zone 649 between the outlet
for orifice 628 and entrance 632 to gas distribution conduit 640.
In this view, the place where oxidizer enters is designated by
elements 684 and 685. Particularly at element 684, oxidizer is
introduced from the fuel supplier 622 side and at element 685, from
the fuel supplier mate 672 side. It is to be understood that said
oxidizer can enter separately from either side, or simultaneously
from both sides.
[0110] The manner in which fuel supplier 622 engages with fuel
supplier mate 672 can take many forms. As described earlier, it
does not require a fluid seal between entrance 632 to conduit 640
and fuel supplier 622. Instead, it may use a gas jet for fluid
supply (or delivery). Since that gas jet need only be properly
positioned at the conduit entrance, the term `connection` is more
broadly defined to also include a more functional versus just a
physical connection.
[0111] The preferred fuel supplier for this disclosure supplies
fuel mixture to the removable burner. This fuel supplier is a
"gas-to-air" type and not a "gas-to-gas" type that must have a
physical connection like the gas-to-gas type connection of Lee U.S.
Pat. No. 5,983,884 that requires a physical fluid seal. Such a fuel
supplier has no utility in this disclosure. That type of prior art
connection is highly prone to sealing problems, and the location of
primary aeration is forced to be nearer the burner head. The latter
requires increased grate heights for an equivalent firing rate, or
a de-rating of the burner. Further, consumer studies have shown an
appliance user's reluctance to make a gas-to-gas connection as
users tend to consider such connections unsafe.
[0112] FIG. 6B shows a fuel circuit similar to that shown in FIG.
6A but with the latter fuel supplier 622 having one or more
orifices 628 that need not be identically sized. As shown, fuel
supplier mate 672 has two gas distribution inlets 632 and gas
distribution conduits 640 for receiving and delivering fuel mixture
652 to burner head 620. Note that fuel supplier mate 672 need not
have two gas distribution inlets or gas distribution conduits. One
may suffice depending on venturi and burner design.
[0113] FIG. 6C shows a fuel circuit similar to FIG. 6A, but with
two fuel suppliers 622 driving a `single` burner head 620
partitioned in two for receiving a fuel mixture from a fuel
supplier mate 672 having two gas distribution inlets 632 and gas
distribution conduits 640. When there are two or more fuel
suppliers, a gas distribution inlet and gas distribution conduit
will be needed for each fuel supplier. In addition, the burner head
for such a configuration should not permit fluid communication
between the two or more gas distribution conduits.
[0114] While no igniter is shown for removable burner 636 in FIG.
6A, 6B, or 6C, most any igniter can be adapted to work with same.
The aforementioned removable burner 636 will also work with cooktop
410 or any other appliance variation from previous FIGS. 1 through
5. Alternately, it can be used without an igniter, such as in a
recreational vehicle (RV) or marine application by igniting gas at
the burner head 620 with a match or handheld lighter.
[0115] While the gas control 630 in FIGS. 6A, 6B and 6C may be
shown as a manual type valve, it will be understood that other
known controls can be substituted for same. FIG. 6D, for example,
is shown using a needle type valve for gas control. Such a valve
operates by changing the effective area of orifice 628 while its
gas velocity remains relatively constant. In that case, gas control
630 could serve as a valve that uses constant pressure upstream of
a "variable-area". It could still have a fixed orifice 628 to
control gas flow, thereby mating gas control 630 with orifice 628
and effectively eliminating the need for a conduit-like element
634. Said valve arrangement is schematically shown as element 630N
in FIG. 6D with all other elements remaining functionally the
same.
[0116] As shown, manual valves are used for gas control 630 (or
630N). But such valves can also be replaced with electronic or
electrical-type equivalents. In other words, alternate embodiments
can use alternate fluid flow devices to control gas flow.
Representative of such devices include those where gas flow may be
controlled by changing, independently or in combination, one or
more of the following variables: fluid pressure differential, fluid
flow cross-sectional area, velocity, viscosity, density, and/or
conduit length. Such variables may be changed transiently (time
dependent) and/or in a "steady state" condition (independent of
time).
[0117] The above gas control 630 (or 630N), may be accomplished
mechanically, electrically, or by both means as in a piezoelectric
movement or by using a so-called stepper motor. Representative
examples of electronic control valves include: a pulse width
modulation ("PWM") valve that turns on and off; a proportional
valve for which flow is controlled in proportion to voltage or
current; a piezo-activated valve; a micro-electromechanical system
("MEMS") and the like. All such valves may be included with this
disclosure and represented by element 630 (630N).
[0118] Operator control 624 can also be electronic, yet still
compatible with the type of gas control 630 or 630N implemented.
Representative examples of electronic operator controls 624
include: an electronic membrane switch; and an electromechanical,
solid-state keyboard such as a capacitive, infrared, piezo-effect
or field-effect device.
[0119] FIG. 6E is a cross sectional schematic of the fuel supplier
622 and fuel supplier mate 672 from FIG. 6A with an alternate way
to manufacture same depending on the connection hardware employed.
This fuel supplier would be similar to the one shown in FIG.
6A.
[0120] In FIG. 6E, a portion of manual gas controller 630 (shown
indirectly supported by appliance 610) supplies gas 646 to orifice
628 at the terminal end of conduit 634 via a gas-to-air type fuel
supply connection. Orifice 628 has an aperture with an axis
parallel to the axial direction of conduit 634. A portion of
conduit 634 has been made removable by incorporating a threaded
seal therein. When gas 646 leaves orifice 628 during normal
operation as a jet, oxidizer 696 enters the gas-oxidizer mixing
zone 649 via oxidizer conduit 685. That conduit is shown as
oxidizer openings into the sides of gas distribution conduit 640. A
gas-oxidizer mixture 652 passes through the entrance 632 of gas
distribution conduit 640. One end 631 of conduit 640
circumferentially surrounds gas conduit 634 before being stopped by
the shoulder 670 on gas conduit 634 of fuel supplier mate 672. This
effectively provides a "functional connection" for providing a
removable burner a gas mixture over a convertible area (shown as
element 601 on cooktop surface 617 indirectly supported by
appliance 610).
[0121] In preceding FIGS. 6A or 6D, elemental end 631 and shoulder
670 were not specifically shown, but such locating (or
interlocking), may be performed, directly or indirectly, by fuel
supplier mate 672. Oxidizer may enter mixing zone 649 via one or
more holes in the vicinity of gas distribution conduit 640 near gas
jet 648 and entrance element 632.
[0122] For "free gas" jets, the typical shape of gas distribution
conduit 640 is a function of fluid flow characteristics for burner
head 620. One typical shape known in the art is a bell shaped,
mouth entrance 632 that necks down to a throat 656 before diverging
for connection to a burner feed conduit like element 651 in FIG.
6H. Such an arrangement is typically referred to as a venturi.
Alternately, gas distribution conduit 640 can have a straight
profile with no internal shape. Much of the shape of gas
distribution conduit 640 depends on the fluid flow characteristics
of burner head used, as is recognized by those skilled in the
combustion art.
[0123] FIG. 6F is a gas-to-air type fuel supply similar to FIG. 6E,
but with no direct physical connection between fuel supplier mate
672 and fuel supplier 622. Instead, the alternative embodiment at
FIG. 6F only shows a fuel supplier mate with a proper gap (much
like a spark plug gap) between fuel supplier 622 and gas
distribution conduit entrance 632. With just that gap, a fuel
mixture may still properly enter entrance 632 of removable burner
636. FIG. 6F is yet another alternate way of manufacturing an
appliance hereby, depending on the connection hardware employed.
Fuel supplier 622 and cooktop surface 617 (with a convertible area
601 over which fuel mixture is supplied to a removable burner), are
each indirectly supported by the appliance 610 as shown.
[0124] In FIG. 6G, fuel supplier 622 is schematically shown
supplying fuel to a removable burner assembly 636 with its fuel
supplier mate 672 connected to fuel supplier 622. This embodiment
of removable burner assembly 636 includes a separately removable,
heat shield 623 that can be made integral therewith. The latter can
thermally protect a cooktop surface, especially when made from
glass or other temperature-limited materials. Removable burner
assembly 636 may further include a grate 618 and burner head 620,
both of which may be separately removable. Meanwhile, manifold 626
is shown fluidly connected for supplying fuel to a manual type gas
control valve 630 (or needle type valve 630N). It is common to
mount a manifold like element 626 to a structural housing similar
to element 412 in FIG. 4. The fuel circuit arrangement of FIG. 6G
may be used in a free standing, slide-in, or drop-in appliance.
[0125] When adjusted by operator control 624, the gas control 630
of FIG. 6G supplies gas to fuel supplier 622 via conduit 634, then
to orifice 628. The latter supplies gas to fuel supplier mate 672.
Although not shown in this Figure, but shown in FIG. 6A, oxidizer
would then enter through holes (element 685) before being entrained
by gas jet and mixed with gas in mixing zone to form a gas-oxidizer
mixture. After receiving the aforesaid mixture, the gas
distribution conduit 640 for fuel supplier mate 672 delivers fuel
mixture to burner head 620. As removable burner 636 is not shown
with its own igniter, a manual lighting of gas-oxidizer mixture at
burner head 620 would be required. Of course, various ignition
means may also be used with the aforementioned configuration.
[0126] FIG. 6H is a cross-sectional schematic of a removable burner
assembly 636 that includes a burner head 620 with cooking vessel
support or grate 618. In this embodiment, gas burner head 620 is in
fluid communication with the burner end 651 to gas distributing
conduit 640. It is not essential that this burner head be
"completely" sealed depending on the designs known in the art. In
FIG. 6H, for example, burner head 620 contains burner ports 658 for
flame stabilization. Fuel supplier mate 672 at end 631 could engage
a fuel supplier like element 422 in FIG. 4A or element 622 in FIG.
6G to gas distribution conduit 640. Holes 685 in that conduit 640
permit oxidizer 696 (as shown in FIGS. 6A and 6D) to enter mixing
zone 649 (also as shown in FIG. 6A and 6D) when connected to a fuel
supplier and operational. As shown, entrance 632 to gas
distributing conduit 640 is a bell that necks down to a throat 656
before diverging to a connection with burner feed conduit 651.
[0127] Other internal gas distribution conduit shapes are also
possible. They can vary with burner head 620 fluid flow
characteristics as discussed above. As used herein, a "removable
burner assembly" may consist of several, integrated components. In
some of the figures, these components are depicted as separate
items. They may be assembled together by a manufacturer, retailer,
installer or the ultimate consumer/appliance purchaser. The
removable burner assembly can also contain fewer physical
components than depicted. For example, if burner feed conduit 651
is a part of grate 618 (i.e. each grate `finger` is hollow and has
burner holes 658) then the grate and the burner head are combined
physically, but function in the same manner as described, such a
grate would be considered integral with burner head 620.
[0128] Returning briefly back to FIG. 3A, removable burner assembly
336 is shown with an igniter 362. Similarly, removable burner
assembly 536 in FIG. 5 has an igniter 562. An integrated (i.e.
other than manual) flame ignition is preferred for most removable
burner configurations especially when used in larger cooking
apparatus/appliances. Various integrated ignition types can be
included with the removable burner assembly, fuel supplier, and
fuel supplier mate assemblies previously shown for FIGS. 1 through
6H.
[0129] FIGS. 7, 8, and 9 all show block diagrams of the disclosure
to clarify the relationship of the elements of the disclosure. FIG.
7 shows that when the removable burner assembly is properly
installed to the appliance (as defined above), an interlock
prevents the burner from moving about during cooking. Such an
interlock would be mandatory for the fuel supplier mate shown in
FIG. 6F. An interlock can assume many different forms. It need not
be one element of the appliance or burner, as shown in earlier
FIGS. 3B and 3C. In FIG. 7, an interlock is positioned between
removable burner assembly 736 and the appliance 710. Removable
burner assembly 736 has at least one burner head 720 and a fuel
supplier mate 772 located by the interlock for properly receiving
fuel from a gas-to-air type fuel supplier 622. In previous figures,
the fuel supplier is part of the fuel circuit, in turn, a part of
the appliance proper.
[0130] FIG. 8 is similar to FIG. 7 except the interlock occurs
between the fuel supplier 822 and fuel supplier mate 872. FIG. 8
better depicts the earlier interlock from FIGS. 3B and 3C.
[0131] FIG. 9 is similar to FIGS. 7 and 8, except that instead of
an interlock between any two elements, a portion of interlock
occurs between: (a) fuel supplier 922 and fuel supplier mate 972;
and also between (b) removable burner assembly 936 and the
appliance 910. In other words, in FIG. 9, an interlock still
occurs, but "in combination". FIGS. 6E, 6G, and 6H also depict such
an interlock. Referring briefly back to FIG. 6E, a "partial"
interlock therein, interlocks the fuel supplier mate to its fuel
supplier, keeping the components in alignment (end 631 of conduit
640 circumferentially surrounding gas conduit 634). A removable
burner can be moved horizontally away from the fuel supplier, thus
only partially interlocking with same. For instance, a burner
assembly with lower supports (or burner feet) can be blocked by a
lip at the edge of the cooktop surface. That would constitute a
partial interlock and such a burner would be effectively
interlocked by the combination of two partial interlocks.
[0132] In FIG. 10A, there is shown an isometric schematic for
removable burner assembly 1036, it is substantially similar to
earlier burners 336 and 536. The representative igniter 1062
depicted is a spark igniter type. It is understood, however, that
still other types may be used, including hot wire or hot
surface-type igniters. Common to all such igniters is a requirement
for electric power. Hence, at least one power lead (depending upon
ignition circuit) will be required to complete the electric circuit
when operably installed.
[0133] Still other types of igniters can also be used herewith.
They include a standing gas pilot type which does not require
electrical power. Such an igniter may be more beneficial for some
situations. In later FIG. 11, a flash tube-type gas pilot is
described in more detail.
[0134] Also in FIG. 10A, sensor 1098 is shown integral with
removable burner 1036. Some agencies require an extra level of
safety with an automatic termination of gas flow (or "shut-off") if
the appliance flame is in an unsafe operating mode (known in the
art as "flame proving means"). Means for automatically terminating
gas flow may require adding a sensor 1098 to detect a flame
presence at burner head 1020. And while it may be feasible to have
just one igniter 1062 and sensor 1098 for a `single` burner head
1020 supplied by one fuel supplier (with no internal partitions
dividing the burner head), there can also be one igniter 1062 and
sensor 1098 for each portion of a burner head 1020 if that burner
head is proportioned to be supplied by multiple fuel suppliers
(having internal partitions).
[0135] Sensor 1098 in FIG. 10A is shown as a separate element for
clarity. It is known in the art to combine such sensors with an
igniter 1062. In some cases, the igniter and sensor are the same
component. A representative model is a spark igniter that also
functions as an electrode when a sensing method is employed for
flame rectification. Suitable types of non-igniter sensors include
a thermocouple, an infrared sensor, a thermistor, and an optical,
including fiber optic sensor, or separate non-sparking electrode
for flame rectification.
[0136] In FIG. 10B, removable burner assembly 1036 has at least one
electrical receiver 1063 with one or more electrical leads or
connectors 1053. The latter are schematically shown as spade types
for clarity. It is to be understood, however, that other types of
leads can be employed for receiving power from a mating, electrical
supply connector for igniter 1062. The same can also be located on
the cooking appliance proper, such as an electrical connector in an
aperture of the cooktop surface, the connector being flush with its
surroundings. An electrical receiver 1063, and its corresponding
electrical supplier mate, can help to locate fuel supplier mate
1072 for removable burner 1036, or can be a portion of an interlock
as was shown in FIGS. 3B and 3C. This is especially true for the
"gas-to-air type" connector described in FIG. 6A through FIG. 9
above.
[0137] Each burner head 1020 in FIG. 10A has an entrance 1032 to
gas distribution conduit 1040 (normally one per burner head). Those
burner heads 1020 can vary in size and the number of ports 1058 per
head. Though not shown, one or more fuel suppliers, and their
corresponding gas distribution conduits 1040, can supply a `single`
head 1020 when that head is duly proportioned. Should only a
`single proportioned` burner head be used, only one igniter 1062 is
needed, much like a single grate 1018 is shared as shown. Such a
`single proportioned` burner head design might more closely
resemble the types of burners used in woks, fish burners, griddles
and the like.
[0138] A sensor, like element 1098, and its sensing circuit may
communicate with an appliance via electromagnetic or photonic
(i.e., non-contacting) means. The types of communications
schematically shown in FIGS. 10A and 10B both use electrical
contact leads. Of course, non-contacting means may also be used
with same provided other means for connecting the removable burner
assembly to the appliance is provided.
[0139] The sensor connector 1054 of FIG. 10A is a part of
electrical receiver 1063. In FIG. 10B, that portion of removable
burner 1036 of FIG. 10A having fuel supplier mate 1072 is more
clearly shown. Two sensor connectors 1054 and two electrical
connectors 1053 are shown, one for each burner head 1020. Since
these electrical connections require a complete circuit, removable
burner assembly 1036 must act as the ground (or neutral connection,
burner assembly being electrical conductive) when the removable
burner is in contact with an already grounded appliance. That
ground need can be avoided, however, if the power supply to igniter
1062 and/or sensor 1098 is isolated and another connector is
provided, or as is common practice in the art, two or more igniters
share one common and power connection. Alternatively, one connector
can be employed for all igniters on a burner assembly if the burner
assembly itself completes the circuit by being ground or the
neutral leg.
[0140] If other external switching circuitry is provided in the
control for removable burner assembly 1036, one may reduce the
number of connectors needed to just one per burner head. A separate
`sensing` electrical receiver can also be employed. That sensor
need not be integral with the electrical receiver as shown,
however. Connector 1054 represents a sensor communication to an
appliance regardless of sensing type and/or communication means.
Also note in this representation the notch 1059 in each connector
1054 and 1053. Such a notch represents in combination with other
removable burner and/or appliance features an interlock for the
removable burner when that removable burner is mounted above a
convertible area that might be planar without an outer drip lip for
completely stopping burner horizontal movement (i.e.
interlocking).
[0141] FIG. 11 shows an alternative ignition arrangement for
removable burner assembly 1136 shown schematically in side view
over cooktop surface 1117 with an imperforate convertible area
1101. Therein, igniter 1162 is depicted as a pilot 1147 (flame).
Any previously shown fuel circuit having a fuel supplier
(represented by element 1122) and a removable burner having a fuel
supplier mate (represented by element 1172) can be used with such
an ignition schematic. Still other components for gas pilot 1147
include a gas pilot conduit 1133 for supplying fuel 1146 from
manifold 1126 to pilot orifice 1127. Once lighted (manually or
otherwise), that pilot flame will ignite gas when a fuel mixture is
supplied to burner head 1120 on removable burner 1136 mounted above
cooktop surface 1117 in convertible area 1101. A small portion of
gas-oxidizer mixture 1152 leaves that burner head unignited via
pilot port 1157. That mixture enters a flash tube terminal end
1137B sufficiently spaced from pilot port 1157. Said terminal end
1137B should be duly sized for its mixture flame velocity to be
greater than its flow velocity. Gas momentum will then force
mixture 1152 to terminal end 1137A of flash tube 1137 for egress in
the vicinity of igniter 1162 (here shown as pilot flame 1147). A
portion of that fuel mixture 1152 will ignite. And the flame front,
with greater velocity in flash tube 1137 than fuel mixture's 1152
flow velocity, will travel to port 1157. There, the flame front
will stop either because burner port 1157 has a greater port
velocity than its flame velocity; or burner port 1157 has a
sufficient quench diameter for stopping flame front propagation. In
either case, the flame will be ignited and maintained at head 1120
of burner port 1157.
[0142] Due to buoyancy and the gap between removable burner head
1120 and flash tube terminal end 1137B, the shape of the aforesaid
flame will be sufficient for preventing it from impinging on the
flash tube. As that flame shape is accessible to other ports 1158
on burner head 1120, it may ignite the gas-oxidizer mixture
egressing from such ports, directly or indirectly, by igniting at
least one such port 1158. In FIG. 11, pilot port 1157 is shown as a
separate burner port. In practice, however, pilot burner port may
be the same as burner port 1158. Such is the case with most
commercial water heater burners.
[0143] Igniter 1162 can be other types, such as a spark, hot wire
or surface igniters, can be used with flash tube 1137, should one
desire to avoid using a gas pilot. Gas pilot line 1133 and pilot
orifice 1127 would not be needed for alternative igniter types. And
while removable burner assembly's flash tube 1137 need not be
included with an appliance, the igniter 1162 can be included as an
integral part of same.
[0144] FIG. 12 shows schematically a cooking appliance 1210 that
operates directly with a removable burner such as that which was
shown in FIG. 10A as assembly 1036. Cooking appliance 1210 is
similar to appliance 510 from FIG. 5, but with a cooktop surface
1217 (including electronic operator control 1224) and panel 1215
removed from structural housing 1212 for better illustrating its
fuel suppliers 1222. In this particular embodiment, each
`gas-to-air type` fuel supplier 1222 includes an orifice 1228 and
electronic valve-type gas control 1230.
[0145] As shown, gas control 1230 of FIG. 12 is an electric
solenoid operated, PWM-type valve directly and fluidly connected to
manifold 1226. It has electrical connectors 1292 for power control.
Gas control 1230 can also connect directly and fluidly to orifice
1228, much the same as was shown as element 630N in FIG. 6B. Fuel
supplier 1222 mates with the fuel supplier mate 1072 to removable
burner assembly 1036, and electric supplier 1273 mates to
electrical receiver 1063. The latter mate supplies electrical power
to burner head igniter 1062. It further communicates with connector
1054 for sensor 1098. Electronic controls could similarly operate
the sensor 1098 or igniter 1062 of removable burner 1036 from FIG.
10A. Yet, it is more typical to manipulate the gas control 1230,
igniter and sensor from an operator control 1224 similar to the way
in which operator control 524 is used over the cooktop 517 in FIG.
5. It is also possible to use separate controls for sensor 1098 and
igniters 1062, herein.
[0146] Sensor 1098 provides flame sensing for an automatic gas
shutoff device. Sensor 1098 in combination with gas control 1230
and electronic control for both elements, can stop gas flow to fuel
supplier 1222. This provides gas shutoff automatically if an
operator would attempt to relocate a removable burner while it is
operating, or if the removable burner is not properly located on
the appliance so as to properly receive fuel mixture from fuel
supplier 1222. In addition, a second redundant gas shutoff device
(not shown) could be placed in fluid communication with the fuel
circuit shown here as manifold 1226 up to orifice 1228. Still other
locations for an electrical supplier 1273 and electrical receiver,
like element 1063 in FIG. 10B, are possible. For example,
electrical supplier 1273 may be integrated with cooktop surface
1217 (an electrical connection made flush with the surface as
described earlier) or its FIG. 5 equivalent 517, so as to contact
an electrical receiver 1063 which may be alternatively located on
the bottom of a removable burner assembly 1036.
[0147] A gas shutoff device can be combined with the previously
shown fuel circuits having a gas-to-air fuel supplier so that when
a removable burner is relocated, gas delivery will be stopped. One
preferred shutoff device of this disclosure employs an
`electromagnetic valve` like those made and sold by Orkli, but for
`flame safety` (otherwise known as a flame safety valve). Such a
valve, is placed in line with and in fluid communication with the
fuel circuit and fuel supplier, and will require gas to flow
through it before reaching the fuel supplier.
[0148] FIGS. 13A through C schematically show an interlock for a
fuel supplier/removable burner assembly which may be moved by
rotation and/or translation from the cooktop for better cleaning
the convertible area beneath.
[0149] An advantage of this disclosure is that removable burners
need not always occupy the convertible area of a cooktop. As such,
that convertible area can be left devoid of apertures and/or other
obstructions that impede cleaning. By "removing" such burners, this
disclosure can allow the same convertible area to also be used as a
food preparation work area. The disclosure does not require total
removal of the burner by disconnecting and storage of that burner,
however. A useful work area can also be accessed with burner
relocation. From earlier schematic discussions, recall how
preferred embodiments of a conduit (like element 634) may be made
flexible and/or include a flexible swivel joint or the like. In
essence, this permits several configurations in which a fuel
supplier can be moved away from the cooktop after use. If a
removable burner assembly was fastened to its fuel supplier, it
could be similarly moved away. In other instances, the removable
burner may be moved by one or more degrees of movement, i.e. by
translation and rotation so that the fuel supplier and burner, or
at least portions thereof, can be stowed after removal. That would
permit the cooktop surface with its convertible area to be more
thoroughly cleaned and used for food preparation.
[0150] One embodiment of this disclosure addresses a removable
burner that can be moved away from the cooktop area, but left
partially attached to the appliance. Such movement is facilitated
with a type of a hinge mechanism interlock. The latter can assume
several forms. A "hinged" interlock can be a separate functional
element or made integral with one or more other elements of the
appliance or removable burner as schematically shown in FIGS. 7, 8,
and 9. For instance, it is conceivable to incorporate such an
interlock design together with the fuel supplier and fuel supplier
mate. Configurations like these are especially advantageous in
small kitchens with a limited amount of storage space. In those
environments, total removal of the removable burner from the
appliance proper may be available but impractical as the loss of
space from storing removed burners elsewhere may outweigh the
advantages of easy cleanup and/or added worktop surfaces.
[0151] FIG. 13A shows a gas-to-air type fuel supplier 1322 with a
portion of a removable burner assembly 1336 operably installed by
an interlock to receive fuel mixture from fuel supplier 1322. More
particularly, connection 1395 permits removable burner assembly
1336 to move mechanically in multiple degrees of movement. Once the
removable burner is moved, convertible area 1301 will be freed from
obstruction thereby allowing easier cleaning of the underlying
cooktop.
[0152] If connection 1395 was raised straight up (i.e.
substantially vertically using just one degree of movement) and
away from groove 1394, removable burner assembly 1336 could be
fully removed from its cooktop as best seen in the start of that
direction of movement in accompanying FIG. 13B. Although not shown,
it will be understood that still other connections which provide at
least one degree of movement for an interlock may be used. For
instance, a horizontal track or groove may be substituted for the
vertical groove 1394 shown. Such movement constitutes one
mechanical degree of movement for the removable burner assemblies
of this disclosure. One degree of movement, shown as mostly linear,
can free the removable burner assembly from its fuel supplier
without having to first flip the unit upwards. That would be a
preferred movement for cleaning a spill, especially if that
removable burner unit contained a heat shield that at least
partially contained such a spill. By keeping a soiled removable
burner substantially horizontal, the removable burner and its
spillage can be lifted away while being kept relatively "flat". The
unwanted contents of that removable burner can then be dumped
remotely before a more thorough cleaning is performed.
[0153] A flipping or mere axial rotation of removable burner
assembly 1336 is the other or "second" degree of movement. That
motion is partially depicted in accompanying FIG. 13C. Note, that
both degrees of movement are independent of one another. They can
also be combined for near simultaneous motion in both directions.
As previously stated, other connections that provide at least one
degree of movement for an interlock may be used. Such interlocks
are preferred in this disclosure as they fulfill the need to
prevent movement of the removable burner assemblies during normal
usage, especially when a vessel gets dragged across the grate. FIG.
13A shows an interlock that requires only one degree of movement
(though more can be used) to remove or install a removable burner
assembly. The flip up movement of FIG. 13C, on the other hand,
shows that a removable burner need not be completely removed from
the appliance for providing a workspace.
[0154] FIG. 14A is a fuel circuit with a gas shutoff 1405. That
same shutoff device can be added to this and other fuel circuit
schematics of this invention in a like manner, but would require
positioning upstream of fuel suppler 1422. As shown, shutoff 1405
is a normally "closed" valve. Such devices are commercially
available and either mechanically or electrically operated. Element
1408 represents a mechanical means to actuate shutoff to an open
state before the flame current produces enough voltage to keep
shutoff 1405 "open". Particularly, element 1408 can be a hand
operated device for initially opening the valve. Alternately,
element 1408 may be electrical means for initially actuating
shutoff to an open state. As shown, shutoff device 1405 is in
proper communication with the fuel supplier 1422 ending at orifice
1428.
[0155] As schematically shown, a representative sensor 1498 like
element 1098 in FIG. 10A, can serve as a thermocouple equivalent
with its current/voltage connected, directly or indirectly, to an
electromagnetic valve. In FIG. 14A, sensor 1498 is a thermocouple
that connects directly to shutoff device 1405 through sensor
connector 1454A on electric supplier 1473 and through sensor
connector mate 1454B on electrical receiver 1463. Other sensor
types may require additional signal conditioning prior to
connection to element 1405.
[0156] For a "gas-to-air" type fuel supplier, electric supplier
1473 and electrical receiver 1463 can be used for properly setting
the distance between orifice 1428 and entrance 1432 of distribution
conduit 1440. Thus, if an electrical supplier mate 1463 for
removable burner assembly 1436 was not "proper" with respect to
electric supplier 1473, fuel supplier mate 1472 would not be proper
relative to fuel supplier 1422 and a voltage/current would NOT be
supplied to shutoff device 1405. That, in turn, would keep its
electromagnetic valve `closed` (electrical circuit open) and
prevent gas 1446 from flowing through the system.
[0157] The present disclosure enables a `flame safety` shutoff
device to be used to stop gas flow by using the electrical
connector (like element 1054 in FIG. 10A and 10B) as a trigger
device for a gas shutoff such as 1405. Also note that a needle type
gas control 1430N in combination with an orifice 1422 can be used
with gas shutoff 1405 if the gas shutoff is upstream of the gas
control 1430N as shown.
[0158] Other known means for gas shutoff can be employed besides
that shown in FIG. 14A. For example, an electromagnetic, electric
solenoid or mechanical shutoff device may be used. Any such device
should permit gas flow (`open` position) when its removable burner
assembly is properly located to the appliance. Otherwise, that
device will stop gas flow (revert to `closed`) if said removable
burner is relocated or otherwise improperly installed. This is a
preferred shutoff means if flame detection is not required.
[0159] The supplemental use of a gas control as an `on-off` valve
or dedicated gas shutoff device is further schematically shown in
accompanying FIGS. 14B, 14C, 14D, 14E and 14F. All show a fuel
circuit similar to FIG. 6A and 6D, with the same elements being
commonly numbered with the same last two digits in the series.
Additional features or elements have been added to the fuel
circuit, however, so that gas flow is stopped when the removable
burner is not properly installed.
[0160] FIG. 14B shows the supplemental use of a gas control as an
`on-off` valve for use with a removable burner that can be rotated
when relocated from the convertible area 1401. Gas control valve
1430 (or 1430N) is closed (`off`) preventing the gas from being
turned on. Such methods have been employed for lids that cover
conventional burners; but here the removable burner 1436, if hinged
to the appliance, accomplishes this function. As indicated in the
schematic, when the removable burner 1436 is mounted above cooktop
surface 1417, and in proper fluid communication with fuel supplier
1422, gas control 1430 can be used for controlling gas flow 1446 to
the fuel supplier 1422. However, when the removable burner 1436 is
relocated, rotation of the trigger 1409 causes element 1408 to
actuate the gas control 1430 to be in an "off" position. Element
1409 can be a mechanical linkage, electrical connection, or any
other means that jointly cooperates with element 1408 to actuate
gas control 1430 via burner relocation.
[0161] FIG. 14C shows a similar fuel circuit schematic to FIGS. 6A
and 6D as well. Herein, the control 1430 (or 1430N) is shown as a
gas control that further serves as a gas shutoff device. The fuel
circuit and supplier of FIG. 14C are similar to that from FIG. 6A
and 6D except that an actuator 1408 and a trigger 1409 similar in
function and description to those shown in FIG. 14B have been added
for removable burner assembly 1436. That system will permit gas
flow (`on`) at gas control 1430, but only when fuel supplier 1422
and fuel supplier mate 1472 are duly engaged, shown schematically
as the `toggle` on the gas control 1430. More importantly, gas
control 1430 will turn `off` if the removable burner assembly is
relocated from convertible area 1401. Thus, trigger 1409 on the
removable burner assembly acts indirectly to enable gas flow. This
fuel circuit is ideal for electronic style gas controls that are
normally closed. The trigger 1409 and actuator 1408 need not be in
physical contact. An electric type switch can be employed for
actuator 1408, but a non-contacting switch could also be employed
that detects the physical presence of the removable burner assembly
1436 and actuates the gas shutoff device.
[0162] FIG. 14D shows a dedicated gas shutoff device 1405 added to
the fuel circuit of FIG. 6A and 6D. Dedicated gas shutoff 1405 is
in proper fluid communication with fuel supplier 1422. It is shown
upstream of gas control 1430, but can be downstream of gas control
1430 if not a needle type, gas control. In that case, element 143ON
could replace equivalent elements 1430 and 1434. As shown, shutoff
device 1405 is in an `on` position when the removable burner
assembly 1436 is properly installed (operable); and `off` when the
latter assembly is not operable. FIG. 3B showed the same sort of
dedicated gas shutoff device at element 305. Such a circuit can
also be employed if the removable burner assembly 1436 is only
rotated away from the convertible area 1401, but not fully removed
therefrom. When the burner is only rotated and not completely
removed, trigger 1409 would cause element 1408 to actuate gas
shutoff device 1405 and stop gas flow.
[0163] FIG. 14E is similar to FIG. 6B but with gas shutoffs added
to the fuel circuit which are selectively `on` when a removable
burner is installed. FIG. 14E demonstrates the flexibility of the
previous fuel circuits. Here gas controls are identified as
elements 1430(1) and 1430(2). In that embodiment, after passing
through first control 1430(1), gas will travel into a secondary
manifold 1426(1) that feeds a plurality of branches (two are
shown). Each branch has a dedicated gas shutoff device 1405 and
orifice 1428. It should be noted that orifices 1428(1) and 1428(2)
do not have to be similarly sized. In that manner, control 1430(1)
can regulate different burners with different maximum firing rates.
Particularly, shutoff 1405(1) can be actuated by element 1408(1)
while actuator 1408(2) is left deactivated and gas shutoff 1405(2)
remains `off`. That would produce a first, `maximum` firing rate.
In the alternative, shutoff 1405(2) can be actuated, and shutoff
1405(1) deactivated, resulting in a second `maximum` firing rate.
Finally, if both shutoffs 1405(1) and 1405(2) were actuated, a
third `maximum` firing rate would result. The preceding principles
can be extended to still other gas supply branches. In FIG. 14E, a
second fuel supplier 1422(2) and corresponding gas supply circuit
part illustrate other possible locations for gas shutoffs shown
here as 1405(3) and 1405(4). In any event, they should all be
located downstream of gas control 1430 if burner firing rates are
to be regulated by selecting different orifice sizes via actuators
1408(3) and 1408(4). Note that if a needle type gas control, like
element 630N in FIG. 6D, were used, the FIG. 14E schematic would
have less utility as a gas control. Such a needle type alone can
advantageously limit maximum firing rates for different burners.
For that sort of arrangement, only one gas shutoff would be
required upstream of a gas control like that shown as element 1430N
in FIG. 14D.
[0164] FIG. 14F schematically shows a dedicated pressure regulator
1481 in its fuel circuit. Prior to this embodiment, all past fuel
circuits have been pressure pre-regulated. If not pre-regulated, it
may be advantageous to require a regulator to also serve as a gas
shutoff device in addition to pressure regulating. That function
could be served by relieving its regulating force, most commonly, a
spring, to near zero with an actuator like element 1408 as shown.
In that manner, element 1409 would not actuate (trigger) element
1408 when fuel supplier 1422 and fuel supplier mate 1472 are
disengaged (or "off"). But when fuel supplier 1422 and fuel
supplier 1472 are engaged, actuator element 1408 and trigger 1409
will engage causing a regulating force to be applied to pressure
regulator 1481 (switching it to "on"). The pressure regulator in
the fuel circuit of FIG. 14F is illustrative only. This disclosure
addresses still other manners of use and/or locations for same.
[0165] FIG. 14G schematically shows a fuel circuit having a
dedicated, `rotating type` gas shutoff device 1405. Device 1405
shuts off gas flow when the removable burner assembly 1436 is
removed from convertible area 1401 by rotation. Trigger 1409 then
causes actuator 1408 to stop gas flow at gas shutoff device 1405.
Note that with this embodiment, the fuel supplier rotates with the
removable burner assembly. Though not shown, a needle type gas
control 1430N can be used here if located downstream of gas shutoff
device 1405.
[0166] FIG. 14H shows the same fuel circuit schematic of FIG. 14D
but with a dedicated, positionally-activated gas shutoff device
1405. The latter device is intended to shut off gas flow when the
removable burner assembly 1436 is positionally removed from
convertible area 1401. Depending on the type of gas control
employed, 1430 or needle style gas valve 1430N (not shown), gas
conduit 1434 or gas manifold 1426 can be flexible. Such an
arrangement lets fuel supplier 1422 rotate with the burner assembly
1436. Also in this embodiment, trigger 1409 and actuator 1408 cause
gas shutoff device 1405 to stop gas flow, shown here, by
rotation.
[0167] FIG. 14I shows a schematic of a fuel circuit having a
`rotating type`, dedicated gas shutoff device 1405. That device
will shut off gas flow when the removable burner assembly 1436 is
removed from convertible area 1401 by rotation. Particularly, that
movement causes trigger 1409 to actuate, in turn causing device
1405 to stop gas flow. Unlike in FIG. 14G, the fuel supplier of
this alternative embodiment does not rotate with the removable
burner assembly. Regardless, rotation of the burner assembly still
triggers gas shutoff device 1405 to be `off` when the burner
assembly is no longer properly installed. Though not shown, a
needle type gas control can also be used here if located downstream
of gas shutoff device 1405.
[0168] In FIGS. 14A, 14B, 14C, 14D, 14E, 14F, 14G, 14H, and 14I, a
gas control with a mechanical-type operator control 1424 is shown.
Electronic operator controls can be employed as well as the
electronic style controls previously mentioned for fuel circuits in
FIGS. 6A, 6B, 6C, and 6D. As previously mentioned, electronic style
gas shutoff devices can also be used, like the solenoid operated,
dedicated gas shutoff device 305 shown in FIG. 3B. In these FIG. 14
alternatives, element 1408 can be an electrical non-contacting
switch that gets "triggered" (element 1409) by the presence of a
burner assembly. As disclosed earlier, element 1408 represent
either mechanical or electrical means, contacting or
non-contacting, to actuate the gas control or shutoff device shown
in these figures.
[0169] Each of these fuel circuits has a gas shutoff device that
can be employed in the various appliance configurations of this
disclosure, including the respective drop-in, slide-in and free
standing cooking appliance models. Of course, some may be more
optimal depending on the manufacturing of the appliance and its
overall configuration.
[0170] In another alternative embodiment, `removable burner
assembly` has been supplemented with an interface for operator
controls. That operator control could be made integral with, or a
separate component of, each removable burner assembly. Hereafter,
such an alternative removable burner assembly will follow the same
designation that has been used for the last two digits, and having
a suffix of WOC indicating the removable burner as a unit `with
operator control`. Of course, a removable burner assembly with
operator control can assume all prior forms like those shown
earlier for all preceding Figures.
[0171] For the next variation of this disclosure, an operator
control previously described and shown as external to convertible
area 101, 201, 301, 401, 501, 601, 1101, 1301, 1401 in the previous
FIGS. 1-14F, may now be included in that very convertible area. For
example, FIG. 15A schematically shows a free standing range like
that from earlier FIG. 1 and 2A, except that an operator control
124 or 224 is no longer a per se part of that appliance. In FIG.
15A, the operator control element has been replaced with an
operator control receiver 1525 and the operator control panel has
been collocated with removable burner assembly 1536WOC as shown in
FIG. 15B as element 1504. In like manner, the same configuration
can be employed for a drop-in appliance, and slide-in appliance
similar to those represented in FIGS. 3A, 4A, and 5, resulting in
an appliance that has no operator controls.
[0172] Thus, all operator controls 124, 224, 324, 424, 524, 624,
and 1424, from prior FIGS. 1 through 14I, are replaced with
operator control receiver designations 125, 225, 325, 425, 525,
625, and 1425 for this new configuration. And, operator control
panel 104, 204, 304, 404, and 504 from prior Figures are totally
removed from the appliance proper, and now part of a removable
burner assembly with an operator control, such as that shown as
element 1504 in FIG. 15B burner assembly 1536WOC.
[0173] To better illustrate the new configuration, FIG. 15B shows a
variation of the earlier FIG. 6A schematic but with operator
control receiver 1525 connected (directly or indirectly), to gas
control 1530. FIG. 15B also shows operator control receiver 1525
interfacing with an operator control transmitter element 1545.
Unlike FIG. 6A, operator control 1524 and control panel 1504 are
part of a newer variation of removable burner assembly 1536WOC. In
FIG. 15B, therefore, control transmitter 1545 connects to its
operator control 1524.
[0174] Just like before, the operator control receiver and
transmitter of FIG. 15B can be physical or functional elements. If
both gas control 1530 and operator control 1524 are electronic, for
example, the interface between operator control transmitter 1545
and receiver 1525 could be electromagnetic and functional as in
using an infrared beam. If gas control 1530 was mechanical,
operator control receiver 1525 could be a valve stem, and operator
control 1524 a mechanical hand knob with operator control
transmitter 1545 a molded insert for stem 1525. In that
arrangement, the `hand knob insert` and `valve stem` interface
would be physical even though no additional elements are involved
and no other physical components would be needed to interface
between these gas and operator controls. In previous schematic
representations, the gas and operator controls did not require a
removable interface/connection. But in this configuration, such an
interface is both necessary and critical. All other fuel circuits
that have been shown can employ this configuration, if elements
1545, 1524, and 1504 are added to the burner assemblies previously
shown.
[0175] A major benefit of the preceding configuration is that it
can completely free an appliance of operator controls regardless of
type. For mechanical controls, proper appliance cleaning can be
further improved. And for mechanical or electronic controls,
overall appliance aesthetics are duly enhanced. Yet another benefit
is that such an arrangement provides an alternative gas shutoff
device when a removable burner is not properly installed.
Specifically, operator control receiver 1525 and transmitter 1545
can be interlocked thus rendering them operable only when removable
burner assembly 1536WOC is properly installed. This is similar to
what was shown in FIGS. 14B and 14C, but with fewer elements. Only
then can the gas control 1530 of this embodiment supply gas 1546 to
fuel supplier 1522. Thus, only when gas control 1530 is in an `off`
position can operator control receiver 1525 and transmitter 1545 be
`unlocked`, thereby permitting removable burner assembly to be
safely and properly uninstalled from this sort of appliance.
[0176] To better illustrate the schematic of FIG. 15B, FIG. 15C
schematically shows a removable burner assembly similar to that of
FIG. 6G except with its removable burner assembly 1536WOC having
additional elements: operator control 1524 and its control panel
1504 and an operator control transmitter 1545 for 1524, which in
turn interfaces with its own controller receiver 1525. And though
removable burner assembly 1536WOC is shown without a heat shield,
one may be included. FIG. 15C has functional equivalents to all
other elements from FIG. 6G, but with elements 1524 and 1545
added.
[0177] Still other cooking appliance configurations are possible as
a result of this disclosure. For instance, the oven of cooking
appliance 110 in FIG. 1 can be replaced with a gas type
refrigerator as is employed by the recreational vehicle (RV)
industry. For that application, the additional space beneath a
cooking appliance cooktop can be used for storage and/or
insulation. Such an appliance would be especially ideal for those
RV's in which gas input to the refrigerator and cooktop are shared.
In a similar fashion, the cooktop of this disclosure can be coupled
to a gas water heater or furnace for still other RV
applications.
[0178] Though not specifically stated, the cooktops from earlier
FIGS. 1 through 5, and FIG. 15A can be made fully removable. Prior
art cooktops, including radiant gas cooktops, were not readily
customizable. With the present disclosure, manufacturers,
consumer/end users can customize, i.e. improve cooktop aesthetics
further by adding to their cooktop surface an image that might be
otherwise damaged with high heat. Also, a glass or glass-ceramic
surface can be employed with one or more prints adhesively
attached, or using a heat-sustainable coating process. In the past,
limited images were possible when made with certain ceramic paints.
But, images using non-ceramic or high temperature coatings were not
possible. The present disclosure permits the use of coatings,
especially low temperature coatings, for a convertible area that is
apertureless. Once applied to these surfaces, such images
themselves can be rendered unobstructed by lifting and/or removing
removable burner units therefrom. And, such cooking appliances need
not be sold with a "forever" cooktop. Instead, they can be sold
separately and incrementally, like the removable burner assemblies
installed over same.
[0179] Once installed, the gas smoothtops of this disclosure can be
made virtually coplanar with any surrounding countertop or
adjacent, peripheral surface. This is especially beneficial, and
aesthetically desirable, for countertops made from stone, granite,
marble, ceramic tile, Corian.RTM. and the like. When one or more
removable burner assemblies are removed from over said cooktop, a
flat and relatively uninterrupted work surface will be fully
exposed.
[0180] This disclosure brings with it a number of unobvious
benefits besides cleaning, aesthetics and utility. As is known in
the art, oxidizer is divided into primary and secondary air for
most burners. Primary air is introduced to the mixture before the
gas is burned. And secondary air is air entrained by the flame
during burning to complete combustion if primary air falls below a
stoichiometric value. All prior art cooking appliances introduced
primary air (normally by gas jet entrainment) from below the
cooktop proper or, from the above the cooktop, in the convertible
area proper. Both have significant disadvantages, which are
resolved with the present disclosure when primary aeration is taken
near the periphery of the convertible area. When a cooking
appliance includes a lower oven as is the case for most
conventional ranges, cooktop gas burner emissions raise still other
design and operation issues for arrangements having primary
aeration. This disclosure overcomes such issues by its ability to
introduce oxidizer (primary air) from above or at least very near
the cooktop surface itself.
[0181] All previously shown configurations of this disclosure allow
primary air to be drawn from above the cooktop and external to the
convertible area. When entraining primary air from above (or close
to the top of the cooktop surface), the burners of this disclosure
are less likely to extinguish when an oven, or adjacent cabinet
door, opens or closes too rapidly. By contrast, known prior art
burners have extinguished prematurely, especially at low firing
rates, because of a compression/rarefaction wave setup by the
cooktop surface similar to a drumhead. Still further, this
configuration permits primary aeration from not only above the
cooktop, but external to the convertible area thereby facilitating
better secondary aeration and reducing grate height requirements
for proper emissions.
[0182] Still another aspect concerns the manufacturability and
assembly of appliances employing the features described above. It
is advantageous to avoid having to mount burners directly onto or
through a cooktop made from glass or glass ceramic. Extra effort,
care and expense are required to make, use, sell, transport and
install appliances having one or more apertures through a ceramic
glass region.
[0183] Yet another aspect arises with the subsequent servicing of
these next generation appliances. With the disclosure described
herein, consumer/end users will be able to self diagnose certain
aspects, preliminarily by switching out burners, i.e., testing them
in different positions for determining whether the problem resides
with a given removable burner or the appliance proper. Ultimately,
this may reduce the number of service calls required as removable
burner assembly issues can be addressed by other means including
mail order replacements, in store drop-offs and/or pickup points of
service.
[0184] Another aspect concerns the modular nature of these
cooktops. This disclosure allows replacement burners to be located
in multiple sites on the same base top. Today's most common range
or cooktop has a matrix of burners (2.times.2). But with the
present disclosure, one can envision a matrix having a (1.times.4)
or even a (1.times.1) burner layout. With such configurations, it
may be possible to prepare food directly in front of the very
removable burner that will be used for cooking same. And such food
preparation can take place at a level nearly coplanar with
surrounding countertops. Finally, with a removable burner
orientation that allows for connections to only the rear
wall/corner of a cooktop, it is less likely that young children
will see the handles of a hot pot or pan, let alone reach up and
pull said cooking vessel down onto themselves.
[0185] The present disclosure permits removable burner assemblies
and a cooktop that may be sold separately but still permit the
rigorous testing for the removable burner, cooktop, and gas cooktop
appliance, i.e. the combination, to obtain the necessary gas agency
approvals by the manufacturer. When first purchased, appliances can
be shipped with a core structural housing that includes all the
necessary wiring and gas supply components required in a particular
jurisdiction or by a particular governmental agency. More and
better quality components, upgrades or "options" can then be
purchased to accommodate a consumer/user's changing tastes, room
decors and cooking skills. For example, if the original cooktop
satisfied a first color scheme but its owner wanted to change (or
update) to a newer, kitchen theme/motif, a replacement cooktop can
be bought and substituted for the initial model. And a damaged
cooktop, especially if glass or glass-ceramic, could be more easily
exchangeable at a lower `per unit`, replacement cost.
[0186] With separately purchased, replaceable and/or removable
parts, and accompanying accessories, greater modularity will only
enhance consumer experimentation with different styles, tastes and
cooking styles. This disclosure will allow consumers to first buy
what they need, with the option of later adding burners, etc. to
accommodate subsequent wants. A user could add a removable wok
burner for oriental cooking, fish burner for Mediterranean style
cooking, and separate burners for grilling, simmering, etc. When
cooking is complete, such removable burners can be removed and
stowed just like a pot or pan, or moved from the convertible area
while still attached to its appliance. In either case, the
convertible area can be left clear and unobstructed for easier and
more thorough cleaning than what is possible with today's
conventional gas cooktops. This disclosure also represents an
improvement over current box "cartridge" systems that although are
modular, are still always installed in the appliance proper.
Further, by having the burner being mounted above, atop or over the
convertible area on the cooktop surface, the removable burners of
this disclosure can be treated and handled more like a cooking
vessel.
[0187] As this disclosure has been described, it will be apparent
to those skilled in the art that the same may be varied in many
ways without departing from the scope of this disclosure. Any and
all such modifications or alternates are intended to be included
within the scope of the appended claims and the equivalents
thereof.
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